Process and apparatus for assembling a bulk container

ABSTRACT

A process and apparatus for assembling a container having first and second sections, the first section having a bottom and a side wall with flaps thereon and a second section having another side wall and lateral end walls thereon. A plurality of rigid skids are secured to the bottom wall of the first container section. The apparatus includes a skid positioning station, a first gluing station, a mechanical fastening station, a second gluing station, and a pressure applying station. A first conveyor transfers a plurality of skids from the skid positioning station to the mechanical fastening station. During this transfer, adhesive is applied to the upper surface of each of the skids. The first container section is placed over the skids and thereafter, means are provided for applying at least one mechanical fastener into each skid and through the first container section, while both are stationary, to thereby mechanically secure each skid to the container section. A second conveyor means then transfers the partially mechanically fastened skids and first container section simultaneously past the second adhesive applying station and to the pressure applying station. During movement to the pressure applying station, adhesive is applied to the upper surface of the flaps of the first container section. Means are provided for stopping the skids and the first container section and the second container section is positioned in such a way that portions of the second container section overly the flaps with adhesive thereon. Mechanical pressure is then applied to the flaps and overlying portions of the second section for adhesively bonding the two container sections together.

United States Patent [191 Heavner et al.

.[ PROCESS AND APPARATUS FOR ASSEMBLING A BULK CONTAINER [75] Inventors: Larry W. Heavner, Glen Ellyn;

Kenneth L. Gidewall, Clarendon Hills, both of I11.

[73] Assignee: Coronet Container, Lombard, Ill.

[22] Filed: Jan. 28, 1974 [21] Appl. No.: 436,870

[52] US. Cl 93/36 M; 29/432; 93/39 R;

93/55; 156/92 [51] Int. Cl. B31B 15/00 [58] Field of Search 93/36 M, 36 R, 39 R, 44,

93/55, 56 R, 56 PD, 36 MM; 156/92; 29/432; 217/69; 229/23 C, 23 A, 23 AB, 49, DIG. l

2,625,085 1/1953 Bergstein 2,766,923 10/1956 DEsposito... 229/23 C 3,514.030 5/1970 Carroll 229/23 R24.220 9/1956 Richardson 229/23 C Primary Examiner-Granville Y. Custer, Jr.

Assistant Examiner-James F. Coan Attorney, Agent, or FirmMolinare, Allegretti, Newitt & Witcoff [57.] ABSTRACT A process and apparatus for assembling a container [451 Sept. 16, 1975 having first and second sections, the first section having a bottom and a side wall with flaps thereon and a second section having another side wall and lateral end walls thereon. A plurality of rigid skids are secured to the bottom wall of the first container section. The apparatus includes a skid positioning station, a first gluing station, a mechanical fastening station, a second gluing station, and a pressure applying station. A first conveyor transfers a plurality of skids from the skid positioning station to the mechanical fastening station. During this transfer, adhesive is applied to the upper surface of each of the skids. The first container section is placed over the skids and thereafter, means are provided for applying at least one mechanical fastener into each skid and through the first container section, while both are stationary, to thereby mechanically secure each skid to the container section. A second conveyor means then transfers the partially mechanically fastened skids and first container section simultaneously past the second adhesive applying station and to the pressure applying station. During movement to the pressure applying station, adhesive is applied to the upper surface of the flaps of the first container section. Means are provided for stopping the skids and the first container section and the second container section is positioned in such a way that portions of the second container section overly the flaps with adhesive thereon. Mechanical pressure is then applied to the flaps and overlying portions of the second section for adhesively bonding the two container sections together.

32 Claims, 43 Drawing Figures PATENTEI] SEP I 6 i975 SHEET RNW FATENTEBSEP 1. 6 ms 3, 905 282 sass; e

PATENTHI SEP 1 5 575 www m NR WNW WNW

QNM wnmw *NN ww T g AW Ag m FATEHTEB SE? 1 5 75 ShEET PROCESS AND APPARATUS FOR ASSEMBLING A BULK CONTAINER BACKGROUND OF THE INVENTION FIELD OF THE INVENTION and DESCRIPTION OF THE PRIOR ART This invention relates to a process and apparatus useful for assembling a container having two container 9 'sections with a plurality of rigid skids mounted on the underside thereof.

The container shown in Heavner US. Pat. No. 3,743,166 and the pallet type container shown in patent application Ser. No. 240,975, filed Apr. 4, I972, by Larry W. Heavner, both relate to pallet type containers wherein the pallet structure is a unitary part of the container. Prior to such constructions it was the common practice in shipping of articles, in bulk, to attach the heavy cardboard container to a suitable pallet, generally made of wood, for supporting the container and articles carried therein for convenient handling by a fork lift truck or like material handling equipment. Usually, the wooden pallets are mechanically attached to the container bottom by staples, nails, and sometimes by banding the container to the pallet. One of the principal drawbacks of these prior art constructions is the high cost involved in the manufacture and the labor involved in the use of these wooden pallets and in similar alternate constructions.

For the most part, containers such as shown in the said Heavner patent and in the said Heavner application have been manually assembled from corrugated cardboard blanks and the skid portions have been manually secured to the bottom of the container. The manual assembly of these containers is particularly difficult because of the large size of the blanks. For example, the type of container shown in the Heavner application is constructed from two sections with one section having a bottom wall and a side wall with two lateral flaps thereon. This section can be as large as 8 inches X 8 inches. The second container section before securement to the first container section, can be as large as 8 inches X 17 inches. Needless to say, the manual handling of corrugated blanks of this size is cumbersome. In addition, at least two or three wooden skids, or the like, must be secured to the bottom wall of the first container section. Any method and apparatus wherein the skids can be secured to the first container section and wherein the two container sections may be secured together with minimal manual handling, and in a convenient, efficient and time saving manner, would be highly desirable.

SUMMARY OF THE INVENTION It is therefore an important object of this invention to provide a unique apparatus and process for the assembling of a bulk container of the type having pallet type skids rigidly secured to the bottom wall of the container.

It is also an object of this invention to provide a method and aparatus for assembling rigid skids to a first container section, and thereafter, assembling a second container section to the first section, in order to form a unitary knock down bulk, pallet type container.

It is a further object of this invention to provide a unique apparatus for assembling a bulk container comprised of two container sections having skids on the bottom thereof, wherein the apparatus is particularly characterized by its simplicity and economy of construction and efficiency in operation.

It is still another object of this invention to provide a unique method and apparatus for efficiently securing a plurality of rigid support members to a single container member and thereafter simultaneously moving all the members while the mechanical securement of the members to the single member is completed.

Further purposes and objects of this invention will appear as the specification proceeds.

The foregoing objects are generally accomplished by an apparatus and method for assembling a container of the type which has first and second container sections, the first container section having a bottom wall and a side wall with flaps thereon, the second container section having another side wall and lateral end walls thereon, and a plurality of rigid skids being secured to the underside of the bottom wall; the apparatus and method includes a skid positioning station, a first gluing station, a mechanical fastening station, a second gluing station and a pressure applying station. A transfer mechanism carries theskids from the skid positioning station to the mechanical fastening station, while means are provided for applying adhesive to the upper surface of the skids during the transfer of the skids to the mechanical fastening station. Initially, at least one mechanical fastener is used to secure each skid to the undersurface of the first container section, while the skids and first section are stationary. The conveyor thereafter conveys the mechanically fastened skids and first container section past the second adhesive applying station and to the pressure applying station, while the second adhesive applying station is applying adhesive to the upper surface of the flaps. Means are provided for stopping and aligning the first and second BRIEF DESCRIPTION OF THE DRAWINGS A particular embodiment of the present invention is illustrated in the accompanying drawings wherein:

FIG. 1 is a top plan view of the front half of the machine used for assembling a plurality of skids to the underside of a first container section and for thereafter assembling a second container section to the first con tainer section;

FIG. la is a continuation of FIG. 1, illustrating the rear half of the machine shown in FIG. 1;

FIG. 2 is a side elevational view of the embodiment of the from half of the machine shown in FIG. I;

- FIG. '2a is a side elevational view of the rear half of the-machine shown in FIG. 1A;

FIG. 7 is an enlarged, partially broken, detail view in end elevation of a stapling mechanism used in the machine of FIGS. 1, la, 2 and 2a:

FIG. 8 is an enlarged sectional view taken along the line 8-8 of FIG. 6 illustrating the vertical guide and support means for the mechanical fastening section;

FIG. 9 is a side elevational, sectional view taken along the line 99 of FIG. 7 showing the stapling mechanism and stop mechanism in side elevation;

FIG. 10 is a sectional, detail view of a portion of the support frame for the stapling mechanism shown in no.9;

FIG. 11 is a sectional view taken along the line 11-11 of the embodiment of FIG. 10;

FIG. 12 is an end elevational view of the stop mecha nism illustrated in FIG. 9;

FIG. 13 is a detail, top plan view of the transfer mechanism used for transferring a skid from the skid positioning station and past the first adhesive applying station;

FIG. 14 is a side elevational view of the embodiment of FIG. 13;

FIG. 15 is an enlarged sectional view taken along the line 15-15 of FIG. 14;

FIG. 16 is an enlarged, detail view, as viewed along the line 16-16 of FIG. 1, of the limit switches and glue applying means for applying glue to the skids;

FIG. 17 is a top plan view of the embodiment of FIG. 16;

FIG. 18 is a detailed. side elevational view of the mechanism for applying glue to the flaps of the first container section;

FIG. 19 is a top plan view of the embodiment of FIG. 18;

FIG. 20 is an enlarged, side elevational, detailed view, as viewed along the line 20-20 of FIG. 1., illustrating the cam and conveyor arrangement used in the transferring of the first container section and skids to the second glue applying station and to the pressure applying station;

FIG. 21 is a top plan view of the embodiment of FIG. 20;

FIG. 22 is a sectional view taken along the line 2222 of the embodiment of FIG. 20;

FIG. 23 is an enlarged detailed view, as viewed along the lines 23-23 of FIG. la, of the opposite end of the conveyor mechanism shown in FIGS. 20-22;

FIG. 24 is a top plan view of the embodiment of FIG. 23;

FIg. 25 is a sectional view taken along the line 2-525 of FIG. 23;

FIG. 26 is a side view of the embodiment illustrated in FIG. 25;

FIG. 27 is an end elevational, detail view of the stop mechanism at the pressure applying station of the machine;

FIG. 28 is an end elevational view of the embodiment of FIG. 27;

FIG. 29 is a detail view of a portion of the frame of the machine;

FIG. 30 is another detail view illustrating the frame of the machine;

FIG. 31 is a further view illustrating the frame of the machine;

FIG. 32 is a side elevational, schematic view of the skid positioning station of the machine;

FIG. 33 is a top plan view of the embodiment of FIG. 32;

FIG.. 34 is a side elevational, schematic view of the mechanical fastening section of the machine;

FIG. 35 is a top plan view of the embodiment of FIG. 34;

FIG. 36 is a top plan view illustrating the second glue applying station and the support for the second container section;

FIG. 37 is a top plan view of the embodiment of FIG. 36;

FIG. 38 is a side elevational view of the pressure applying station of the machine;

FIG. 39 is a top plan view of the embodiment of FIG. 38;

FIG. 40 is a perspective view of the two container sections with skids attached thereto while being moved to the assembled condition; and

FIG. 41 is a perspective view from the bottom side of an asembled bulk container.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIGS. 40 and 41, there is shown one pre ferred assembled container, generally 10, which is constructed by our method and apparatus for assembling bulk carton containers. The container 10 shown in the drawings is the type shown in U.S. Pat. application Ser. No. 240,975, filed Apr. 4, 1972, by Larry W. Heavner. Although the method and apparatus to be described herein will specifically relate the the manufacture and assembly of the container 10, it is to be understood that the described method and apparatus are also useful in connection with the manufacture of other similar types of containers, and furthermore components of the apparatus and steps of the described process may well be used in connection with the manufacture and assembly of other types of containers.

Referring to FIGS. 35, 40 and 41, the container 10 is comprised of a first container section, generally 12, and a second container section, generally 14. Referring to FIG. 35, the first container section includes a bottom wall 16, a side wall 18, flaps 20 hingedly secured to the side wall 18, and a top flap 22 which is hingedly connected to the side wall 18. The second container section 14, as seen best in FIGS. 394l, includes a pair of end walls 24, a side wall 26, a top flap 28, a bottom flap 30, a pair of top end flaps 32, and a pair of bottom end flaps 34. A plurality of rigid skids 36, made from wood or other rigid material, are rigidly secured to the outer face of the bottom wall 16 of the first container section 12. The inventive method and apparatus are directed to the assembly of the container 10 wherein the two container sections 12 and 14 are assembled together and the skids 36 are assembled to the first container section 12.

I. THE CONTAINER ASSEMBLY METHOD The method for assembling the container 10 can best be understood by referring to FIGS. 32 39, which schematically illustrate the steps comprising the inventive method. The apparatus, generally 38, which will be described in detail hereinafter by referring to FIGS. 1 31, includes a skid positioning or loading station, generally 40, a first adhesive applying station, generally 42. a mechanical fastening station, generally 44, a second adhesive applying station generally 46, and a pressure applying station, generally 48.

Referring to FIGS. 32 and 33, the rigid wooden skids 36 are first located or manually positioned at the skid loading station 40 of the apparatus 38. In FIG. 32, the

skids are shown in side elevation while in FIG. 33, the

skids 36 are shown in top plan view. A plurality of skids 36 are used in order to provide suitable support for the bottom wall 16 of the first container section 12 since the container is constructed to receive heavy articles, for example, automobile engine blocks.

After the rigid skids 36 are manually positioned at the skid loading station 40, they are conveyed or transferred past the first adhesive applying station 42. At the adhesive applying station 42, adhesive is applied to the upper surface of each of the skids 36. Any suitable adhesive useful for securing wood to cardboard or paper can be used, such as an expoxy or other type of cold setting adhesive.

Referring to FIGS. 34 and 35, the skids 36 are transferred to the mechanical fastening station 44 from the skid loading station 40. The movement of the skids 36 from the skid loading station 40 and past the adhesive applying station 42 is stopped momentarily at the mechanical fastening station 44. The first container section 12 is laid or positioned over the skids 36. Specifically, the bottom wall 16 is positioned over the skids 36 because the skids 36 provide rigid support for heavy articles, as engine blocks, to be shipped within the container 10. In the embodiment shown, three skids 36 are used. The first container section 12 is positioned so that the lateral ends of the bottom wall 16 are generally aligned with the outer edges of the outer paif of skids 36, while the central skid 36 is positioned substantially v intermediate the outer skids 36.

After the first container section 12 has been properly positioned over the skids which have had adhesive applied thereto, a mechanical fastener, as a staple, is driven through the bottom wall 16 and into the leading portion of each of the skids 36. This is an important aspect of the described method so that a plurality of skids 36 and the container section 12 may be easily moved simultaneously for further processing. Although adhesive has been applied to the upper surface of the skids 36, a mechanical fastening of the skids to the container section is highly desirable in order to hold the skids and container sections together for a sufficient period of time for the adhesive to set and firmly bond portions of the bottom face of the bottom wall 16 to the skids. The single staple, nail, or other type of mechanical fastener, which is driven through the container section 12 and into the leading edgesof each of the skids 36 enables the desired simultaneous movement of the first container section 12 and attached skids 36.

Once each of the skids 36 has been properly secured by one mechanical fastener to the first container sec- .tion 12, the first container section 12, and the assembled skids 36 are carried towards the pressure applying station 48. During this transfer, a plurality of spaced mechanical fasteners, such as staples or nails, are sequentially driven through the bottom wall 16 and into each of the skids 40 in order to provide firm mechanical securement between the bottom wall 16 and the rigid skids 36. Not only do the mechanical fasteners provide mechanical securement between the skids and the container section, but they also cooperate with the set adhesive to provide an exceptionally strong bond between the skids and the first container section.

Referring to FIGS. 36 and 37, the mechanically assembled skids 36 and first container section 12 are carried along the same path of travel and past the second adhesive applying station 46. At this station, adhesive is applied to the upper face of the flaps 20 connected to the side wall 18 of the first container section 12.

As seen in FIG. 36, the second container section 14 is generally aligned and supported above the first container section 12 at the second adhesive applying station 46. Adhesive which is applied at the second adhesive applying station 46 is provided for joining the container sections 12 and 14 together.

After the adhesive has been applied along the upper face of the flaps 20 of the first container section 12, the second container section 12 is positioned so that a folded outer surface portion of the end wall 24 is aligned above and adjacent each of the flaps 20 which have adhesive thereon. When the outer edge of the side wall 26 is thus positioned, movement of the first container section 12 ceases and mechanical pressure is applied at the pressure applying station 48 along the entire area of contact between the flaps having the adhesive or glue thereon and the adjacent outer edge of the end walls 24 of the second container section 14. Pressure is applied for a period of time sufficient to permit adhesive to bond the two container sections together when a suitable adhesive, preferably a resin type of adhesive is used. About ten seconds is generally sufficient for obtaining a sufficient bond between the two container sections to enable further handling of the container 10, when for example, a conventional resin adhesive is used.

It is seen from the foregoing that our process for assembling the container 10 is simple, effective, and requires little manual handling.

2. THE APPARATUS Preferably, the apparatus 38, shown in FIGS. 1 31, is used for practicing the above described process. Referring to FIGS. 1 and la, in particular, the skid loading station 40, the first adhesive applying station 42, and the mechanical fastening station 44 are shown, with a portion of the second adhesive appling station 46 also being shown. FIGS. 2 and 2a, show the second adhesive applying station 46 and the pressure applying station As indicated previously, the apparatus 38 generally includes the skid loading station, generally 40, the first adhesive applying station, generally 42, the mechanical fastening station, generally 44, the second adhesive applying station, generally 46, and the pressure applying station, generally 48. A frame, generally 50, supports all of the operating parts of the apparatus 38. The frame 50 constitutes an important part of the invention because of its great versatility in usefulness with a variety of container sizes. The apparatus 38 is constructed and arranged to assemble the container 40, from first and second container sections 12 and 14 of widely varying widths and lengths. Also, if desired, the apparatus 38 may be operated so as to vary the number of skids 36 which are secured to container 10. As will be described hereinafter, the frame 50 and the various operating stations of the apparatus 38 may beadjusted, as longitudinally and transversely, to accomodate varying sizes of container sections. 7

Referring to FIGS. 1, la, 2, 2a and 5, the frame 50 includes an elongated lower frame section, generally 52, a mechanical fastening section support frame, generally 58, positioned intermediate the opposite ends of the lower frame 52, an overhead frame generally 60, and a rear frame section, generally 62, for supporting the pressure applying section 48 of the apparatus 38.

The lower frame sections 52 includes a pair of spaced elongated horizontal channel members 64 which are rigidly interconnected at their opposite ends by tranverse end channels 66. A plurality of transverse members 68 are secured to the frame section 52, one being secured to the forward channel 66 and the other being spaced along the front of the side channels 64. The transverse members 68 project laterally beyond the side members 64. A plurality of upright supports 70 support the lower section 52 in a substantially horizontal, fixed position.

The mechanical fastening section support frame is movable longitudinally of the lower frame 52. Referring to FIGS. 2 and 6, the mechanical fastening section frame includes a pair of upright supports, generally 72, which are interconnected by a cross frame 74, which, in turn, is rigidly interconnected to the upper ends of the upright supports 72. The lower ends of the upright supports 72 are rigidly interconnected to a lower longitudinal support 76 at the central portion thereof. Each longitudinal support 76 rotatably carries a pair of spaced wheels 78 at the outer ends thereof, the wheels rollably engaging a pair of transversely spaced tracks 80. The tracks 80 are parallel to the longitudinal axis of the apparatus 38 and frame 50. By this structure the overhead frame 60 is movable to a desired position relative to the forward end of the apparatus 38 in order to accomodate skids 36 of varying lengths and first container sections 12 of varying sizes.

As will be described hereinafter, each mechanical fastener assembly, generally 82, supported by the mechanical fastening support frame 58, may be adjusted transversely so as to be adjusted to a desired positive relative to the skids 36 and to the first container section 12. Referring to FIGS. 29, 30 and 31, the lower frame section 52 is adjustable relative to the longitudinal axis of the apparatus 38, so that the relative position between the skids 36 and fastening assemblies 82 may be changed. In this regard, the side channels 64 are adjustably secured by clamps 84 to a transverse member 86. The transverse member 86 is adjustably secured to the upper end or the upright support 70 by a clamp 88 in order that the support channels which support the first container section 12, as seen in FIG. 29, may be adjusted inwardly and outwardly relative to the longitudinal axis of the apparatus 38. Overhead transverse support channels 90 mechanically support the first container section 12 in position above the skids 36 as the skids 36 are transferred to the mechanical fastening station 44.

The rear frame section 62, as seen best in FIGS. 1, 1a, 2 and 2a, includes a raised section 92, and a bottom section 94. The raised section 92 includes end and intermediate upright support columns 96 which generally define the lateral extremities of the apparatus 38, as"

rigid by longitudinal beams 99 secured to the outer upper surfaces of the cross beams 98. Longitudinal support beams 100 rigidly interconnect the upper ends of each front column 96 and each intermediate support column 96, as seen best in FIGS. 2 and 2a.

The botton or lower section 94 of the rear frame section 62, as seem best in FIGS. 1a, 2a and 5 includes a pair of lateral support frames 102, which support the lateral edges of the second container section 14 as seen best in FIG. 5. The lateral frames 102 each include upright supports 104 and transverse supports 105 which are rigidly interconnected to the upright supports 104. A rigid longitudinal side guide member 108 is secured to the upper surface of the frame 102 and is laterally adjustable thereon in order to guide the lateral edges of the second container section 14 into proper position at the pressure applying station 48, regardless of the particular width of the container section being guided thereon.

The skid loading station 40 is seen best in FIG. 1, 2, l3, l4 and 15. Referring to FIGS. 1 and 2, the skid loading station 40 includes a plurality of spaced, longitudinal skid supports, generally 110, and a conveyor mechanism, generally 112.

Each skid support 110, as seen best in FIG. 15, includes a pair of longitudinal angle members 114 and 116, which cooperate with each other to define an upwardly opening skid receiving channel 118. An upright support column is rigidly secured to the underside of the channel defining members 114 and 116 to vertically support the outermost end of the skid support assembly 110. The angle member 114 of each pair of angle members 114 and 116 is laterally adjustable relative to the angle member 116 so as to accomodate skids 36 of varying widths. A plate 122 is secured to the underside of the angle member 116 and a clamp member 124 is secured to the transverse plate 122 so as to adjustably position the angle member 114 relative to the angle member 116 for accomodating skids 36 of various widths. The rear portions of the angle members 114 and 116 are rigidly secured to the lower frame section 52 as best seen in FIGS. 1 and 2.

The conveyor mechanism 112 includes an air drive cylinder 126 which is rigidly secured at its inner or rear end to an angle support 128 which is rigidly mounted on one of the channel defining angle members 114 and l 16, as seen in FIG. 1. The longitudinally elongated air drive cylinder 126 in its fully extended position, is as long as the angle members 1 l4 and 1 16 of the skid support assembly 110. A piston rod 130 projects frontwardly from the air drive cylinder 126 and is rigidly secured at its outermost end to a pusher plate 132, as seen in FIG. 15. The pusher plate 132 comprises an upright plate positioned within the channel 118 for moving a skid 36 forwardly past the adhesive applying station 42 to the mechanical fastening station 44.

As seen in FIGS. 13, and 15, the pusher plate 132 is interconnected to the piston rod 130 by a connecting member 134. The connecting member 134 includes an upright plate portion 136 and a transverse, horizontal plate portion 138, which is integral with the upright plate 136. The upright plate 136 is fixedly secured to the outer end of the connecting rod 136 by a nut 140, which is threadably secured to the threaded outer end of the rod 130. As seen in FIG. 15, the transverse horizontal plate 138 is rigidly secured, as by welding, along one edge to the upright pusher plate 132. The movement of the piston rod 130 of the air cylinder 126 imparts reciprocal movements to the pusher plate 132 on the skid support 110 for first moving the skids along a desired path of travel and the the mechanical fastening station 44. In order to properly guide the movement of the pusher plate 136, a conveyor guide assembly, generally 142, is provided.

' The conveyor guide assembly 142 includes an overhead support plate 144 which is secured at its outer end to a support member 146, which, in turn, is rigidly secured to the front or outer end of the skid support 1 10 and specifically to the front or outer ends of the angle members 114 and 116, as seen in FIGS. 13 and 14. The support plate 144 extends for the entire length of the skid support 110 and is positioned generally above the air cylinder 126. The inner or rear end of the support plate 144 is secured to the same angle support 128 to which the air cylinder 126 is connected. as best seen in FIG. 1.

As seen in FIG. 15, the underside of the longitudinally elongated horizontal support plate 144 has an angle member 148 fixedly secured to the underside thereof. The upright portion of the angle member 148 is spaced from and aligned directly above the upright portion of the angle member 116 for defining an elongated, horizontal slot 150 therebetween. The width of the slot is such as to permit the passage therethrough of a horizontal or transverse portion 138 of the connecting member 134 so that the verticalposition of the pusher plate 132 is properly guided in the vertical direction.

Four sets of rollers 152 are rotatably carried by the transverse plate 138 of the connecting member 134. The rollers 152 are carried on upright axes 154 with the roller guide 152 on each axis 154 being positioned on opposite sides of the transverse plate 138. As seen in FIG. 13, the outer periphery of each of the rollers 152 is spaced opposite another cooperating roller on opposite sides of the upright portions of the angle members 114 and 148 for providing smooth movement for the pusher plate 132 as it tranfers a skid 36 to the mechanical fastening station. A support block 156 is rigidly secured to the underside of the central portion of the transverse plate 138 and a threaded shaft 158 is threadably received therein. The shaft 158 is horizontally and transversely positioned relative to the longitudinal axis of the machine axis. A roller 160 is carried on the shaft 158 and the outer periphery thereof rides on or bears against the upper surface of the horizontal portion of the angle member 114 for vertically supporting the pusher plate assembly 132 during movement thereof.

The adhesive applying station 42 is seen best in FIGS. 1, 2, 16 and 17. The adhesive applying station 42 includes a support, generally 162, a glue attachment, generally 164, a start limit switch, generally 166, and a stop limit switch, generally 168. The support 162, as seen in FIG. 16, generally includes an upright plate 170 having flanges 172 thereon. The flanges 172 include lower lips 174 which are secured, as by welding, to the upper surface of the horizontal, elongated support plate 144 of the skid support assembly 110.

The glue attachment 164 includes a transverse shaft 176 which is fixedly mounted on the support plate 170 as seen in FIG. 17, and which projects laterally therefrom and is positioned generally above the skid channel 118. A support arm 178 is rotatably carried on the shaft 176 and projects forwardly and slightly downwardly therefrom, as seen in FIG. 16. A coil spring 180 is mounted on the shaft 176 and acts to normally bias the arm 178 in a donward direction and towards a skid 36 being moved along the skid channel 118. A glue gun 180, of conventional design, is mounted on the arm 178 with a glue applicator 184 being located at the lower surface thereof. As conventional openings are provided therein for dispensing glue therethrough, the adhesive or glue passes through a hose or line 186 which is interconnected to a pressurized glue source (not shown). The spring 180 normally maintains the applicator 184 in engagement with the upper surface of the skid 36 so as to assure continuous application of the glue or adhesive to the upper surface of the skid.

The start switch 166 includes a switch block 188 which is fixedly mounted to one face of the support plate 170 and a switch arm 190, normally biased in a downward direction is mounted thereon. The switch arm 190 is movable between a downward pivoted position below the upper surface of a skid 36 and an upward position, as seen in FIG. 16, when the limit switch arm 190 is in contact with the upper surface of the skid 36. As the leading edge of the skid 36 engages the downwardly biased arm 190 of the start switch 166, the switch is actuated and pressure is applied to the glue source so that glue is applied to the upper surface of the skid through the applicator 184.

The stop switch 168 is generally of the same construction as the start switch 166 and includes the support block 188 and arm 190. In both cases, the roller portion or lower end of the arm 190 is movable or pivotable in and out of engagement with only the upper surface of the skid 36. In the case of the stop switch 168, it is particularly important to avoid contact with the glue. For this reason the roller 192 is offset from the glued section. When the trailing edge of the skid 36 passes the stop limit switch 168, the application of adhesive or glue to the skid is stopped. A glue attachment 164 is provided for applying adhesive or glue to the upper surface of each skid 36, as seen in FIG. 1. Glue is continuously applied from the attachment 164 as the skid 36 passes thereby.

The skids 36 continue their movement along the desired path of travel, past the first adhesive applying station 42, by action of the conveyor mechanisms 112. This movement continues until the mechanical fastening station 44 is reached. At this time, each of the skids 36 remains stationary for a brief period of time.

As seen in the schematic drawings of FIGS. 34 and 35, the first container section 12 is positioned directly on top of the skids 36 with the lateral edges of the bottom surface of the bottom wall 16 being aligned with the lateral edges of the two end skids 36 while the rear edge of the bottom wall 16 is aligned with the trailing ends of the skids 36. The first container section 12 may be manually positioned on the skids 36, although suit able equipment could feed the first container section 12 into the desired position for stapling or mechanical fastening. The mechanical fastening station 44 is best seen by referring to FIGS. 1 4 and 6-12.

As described earlier, one mechanical fastener assembly 82 is provided for driving staples or the like through the first container section 12 and into each one of the leading edges of the skids 36. This portion of the appa ratus and process is an important feature of the invention. While the skids 36 are stationary, with the first section 12 thereon, one staple only is driven through 

1. Apparatus for assembling a container having first and second sections and having a plurality of rigid skids secured to the underside thereof, said apparatus comprising, in combination, a skid positioning station, a first gluing station, a mechanical fastening station, a second gluing station, a pressure applying station, means for transferring a plurality of said skids in aligned and spaced relationship from said skid positioning station, to said mechanical fastening station, means for applying adhesive to the upper surface of each of said skids during the transfer thereof to said mechanical fastening station, means for applying one mechanical fastener into each skid, and through said first container section, means for conveying said partially assembled skids and first container section simultaneously from said mechanical fastening station and past said second adhesive applying station while applying additional mechanical fasteners into each of said skid and through said first container section, means for applying adhesive at said second adhesive applying station to portions of said first container section, means for stopping and positioning said first and second container sections so that portions of said second container section overly said portions of said first container section having adhesive thereon, and means for applying mechanical pressure to said first and second container sections where said adhesive has been applied for setting said adhesive and thereby adhesively securing said first and second container sections together.
 2. The apparatus of claim 1 wherein said skid positioning station includes a plurality of laterally aligned support means for said skids, and said transferring means is operatively associated with said skid support means.
 3. The apparatus of claim 2 wherein said transferring means comprises an air cylinder drive means, and a pusher plate connected to said air cylinder drive means for engaging said skids and for moving said skids from said skid positioning station.
 4. The apparatus of claim 1 wherein said first gluing station includes a glue applicator, means for normally biasing said glue applicator into contacting relationship with the upper surface of said skids, and switch means for starting and stopping the flow of glue through said applicator.
 5. The apparatus of claim 1 including a Frame for supporting said skid positioning station, said first gluing station, said mechanical fastening station, said second gluing station, and said pressure applying station, said frame including means for adjustably mounting said stations for accommodating skids and container sections of varying sizes.
 6. The apparatus of claim 1 wherein said mechanical fastening station comprises frame means, a plurality of mechanical fastening devices mounted on said frame means over said skids for applying said mechanical fasteners through said container section and into each of said skids.
 7. The apparatus of claim 6 wherein said mechanical fastener device includes means for controlling the number and spacing of fasteners driven into each of said skids.
 8. The apparatus of claim 1 wherein said second gluing station comprises a glue applicator means normally biased against said second container section portion, and switch means for starting and stopping the application of glue through said glue applicator means.
 9. The apparatus of claim 1 wherein said pressure applying station includes an overhead frame means, and a pressure beam vertically reciprocally mounted on said frame means for movement in and out of pressure applying relationship with said overlying container sections.
 10. The apparatus of claim 1 wherein said conveying means comprises a pair of chain conveyors including means secured thereto for engaging said first container section and for conveying said first container section and said skids from said mechanical fastening station to said pressure applying station.
 11. Apparatus for assembling a container having first and second sections, said first section having a bottom wall and a first side wall with flaps, said second section having a second side wall and lateral end walls, and a plurality of rigid skids secured to the underside of said bottom, said apparatus comprising, in combination, a skid positioning station, a first gluing station, a mechanical fastening station, a second gluing station, and a pressure applying station, means for transferring a plurality of said skids in aligned and spaced relationship from said skid positioning station to said mechanical fastening station, said first gluing station including means for applying adhesive to the upper surface of each of said skids during the transfer thereof to said mechanical fastening station, means for applying one mechanical fastener into each skid and through said first container section, means for conveying said partially mechanically fastened skids and said first container section simultaneously past said second adhesive applying station and to said pressure applying station, said second gluing station including means for applying adhesive to the upper surface of said flaps, means for stopping and positioning said first and second container sections so portions of said second section overly said flaps with adhesive thereon, and said pressure applying station includes means for applying mechanical pressure to said flaps with adhesive thereon and overlying portions of said second section for setting said adhesive and adhesively securing said first and second container sections together.
 12. The apparatus of claim 11 wherein said skid positioning section includes a plurality of laterally aligned support means for said skids, and said transferring means is operatively associated with said skid support means.
 13. The apparatus of claim 12 wherein said transferring means comprises an air cylinder drive means, a pusher plate connected to said air cylinder drive means for engaging said skids and moving said skids from said skid positioning station.
 14. The apparatus of claim 11 wherein said first gluing station includes a glue applicator, means for normally biasing said glue applicator into contacting relationship with the upper surface of said skids, and switch means for starting and stopping the flow of glue through said applicator.
 15. The apparatus of claim 11 including a fraMe for supporting said skid positioning station, said first gluing station, said mechanical fastening station, said second gluing station, and said pressure applying station, said frame including means for adjustably mounting each of said stations for accommodating skids and container sections of varying sizes.
 16. The apparatus of claim 11 wherein said mechanical fastening station comprises frame means, a plurality of mechanical fastening devices, mounted on said frame means over said skids for applying said mechanical fasteners through said container section and into each of said skids.
 17. The apparatus of claim 16 wherein said mechanical fastener device includes means for controlling the number and spacing of fasteners driven into each of said skids.
 18. The apparatus of claim 11 wherein said gluing station comprises a glue applicator means normally biased against said second container section portion, and switch means for starting and stopping the application of glue through said glue applicator means.
 19. The apparatus of claim 11 wherein said pressure applying station includes an overhead frame means, and a pressure beam vertically reciprocally mounted on said frame means for movement in and out of pressure applying relationship with said overlying container sections.
 20. The apparatus of claim 11 wherein said conveying means comprises a pair of chain conveyors including means secured thereto for engaging said first container section and for conveying said first container section and said skids from said mechanical fastening station to said pressure applying station.
 21. Apparatus for assembling a container having first and second sections said first section having a bottom and side flaps, and a plurality of rigid skids on the underside of said bottom, said apparatus comprising, in combination, means for applying adhesive to the upper surface of each of said skids, means for thereafter mechanically securing said bottom of said first section to the upper surfaces of said skids with said adhesive thereon, means for applying adhesive to the upper surface of each of said flaps of said first section, means for stopping and positioning said first and second container sections so portions of said second section overlie said flaps with adhesive thereon, and means for applying mechanical pressure to said flaps and overlying portions of said second section until the adhesive thereon has set for securing said first and second container sections together.
 22. The apparatus of claim 21 wherein said adhesive applying means includes switch means for starting and stopping the application of adhesive to said skids and said flaps.
 23. The apparatus of claim 22 wherein said mechanical securing means includes control means for applying one mechanical fastener only through said first container section and into each of said skids while said first container section and said skids are in a fixed position and means thereafter convey said partially assembled skids and first container section while multiple mechanical fasteners are inserted through the first container section and into each of said skids.
 24. The apparatus of claim 21 including first conveyor means for carrying said skids past said skid adhesive applying means and to said mechanical securing means, and second conveyor means are provided for transferring said partially assembled first container section and said skids from said mechanical securing means past said flap adhesive applying means and to said mechanical pressure applying means.
 25. In apparatus for assembling a container to a plurality of rigid members, said apparatus comprising, in combination, means for applying adhesive to said rigid members, means for moving said rigid members along a path of travel relative to said adhesive applying means while said adhesive applying means applies adhesive to said rigid members, means for applying a single mechanical fastener through said container and into each of said rigid membeRs while said rigid members and said container are in a stationary condition, and means for thereafter simultaneously moving said rigid members and said container along a second path of travel while said mechanical fastener applying means applies multiple additional fasteners through said container and into each of said rigid members.
 26. The apparatus of claim 25 wherein said adhesive applying means includes means for controlling the application of adhesive to said rigid members.
 27. The apparatus of claim 25 wherein said rigid member moving means includes a plurality of laterally spaced support members for supporting said rigid members during movement along said path of travel and air cylinder drive means are mounted on each of said support means for moving said rigid members.
 28. The apparatus of claim 25 including means for applying multiple mechanical fasteners through said container as said rigid members and container is being moved along said second path of travel.
 29. A process for assembling a container having first and second sections, said first section having a bottom and side flaps, and a plurality of rigid skids secured to the underside of said bottom, said process comprising the steps of aligning a plurality of said skids at a first station, transferring said skids to a second station, applying adhesive to the upper surface of said skids during movement thereof from said first station to said second station, stopping the movement of said skids at said second station, placing said first container section directly on top of said skids, applying one mechanical fastener only into each of said skids and through said first container section for mechanically securing each skid to said container section, and thereafter moving said skids and said container section simultaneously along a path of travel.
 30. The apparatus of claim 29 including the step of applying a plurality of mechanical fasteners into each of said skids and through said first container section during movement of said skids in said path of travel.
 31. The process of claim 30 including the further step of applying adhesive to said flaps and thereafter positioning said second container section over said glued flaps.
 32. The method of claim 31 including the step of applying mechanical pressure to said first and second container sections at the location where said flaps have adhesive thereon, and where portions of said second container section overly said flaps, said mechanical pressure being applied until said first and second container sections are securely interconnected as said adhesive sets. 